Increasing Aquatic Feed Production Through Plant Audits “Aquafeed Horizons”

What is the Global Seafood Market? 1)Estimated at more than US$ 100 billion per year (130 million ton) 2)30% of seafood production is from aquaculture 3)World demand is expected to increase by up to 3% per year 4)Fresh water aquaculture accounts for 58% of output 5)Marine aquaculture accounts for 42% of output

Where is Aquaculture Conducted? Global RegionSeafood Production (million tons) Asia37.0 Europe2.0 Americas1.2 Africa0.3

Extruder barrel DDC Preconditioner Live bin Feeder system Extruder Cut-A-Way

Factors That Potentially Limit Capacity of Extruders 1) Preconditioning capacity 2) Available power to the extruder 3) Volumetric capacity of extruder 4) Open area in die 5) Down time and Usable Product 6) Upstream/down stream processing Extrusion Line Audit

STARCH GELATINIZATION DURING PRECONDITIONING

Influence of Time and Moisture on Starch Gelatinization in DDC Preconditioners

Comparison of Methods for Determination of Starch Gelatinization 1)DSC uses a 20mg sample versus 500mg in enzyme method 2)DSC requires pure starch source and a raw sample for accurate sample analysis 3)DSC method gives inflated values compared to enzymatic method used by most cereal chemists 4)DSC method has poor correlation to digestibility Method of determining % cook Starch Gelatinization (%) DSC method57.8 Enzyme Susceptibility method used by Wenger 40.0

To Increase Preconditioning Capacity 1)Increase preconditioner size 2)Increase existing preconditioner fill by adjusting beater configuration 3)Add Retention Time Control System (RTC) 4)Increase energy inputs in extruder Extrusion Line Audit

Adjust beater configuration to increase preconditioner fill

Benefits of RTC (Retention Time Control) Preconditioning 1)Instant display and control of retention time to produce desired product quality 2)Constant rate discharge of feed upon shut down to increase usable product 3)Reduce waste and off-spec product during startup 4)Significant potential reduction in steam usage to produce equivalent product 5)Time/temperature documentation 6)Increase retention time of existing preconditioner

1500 liter DDC Preconditioner Retention Time Control Performance Specification

EXTRUSION SYSTEM ENERGY INPUTS

Factors That Potentially Limit Capacity of Extruders 1) Preconditioning capacity 2) Available power to the extruder 3) Volumetric capacity of extruder 4) Open area in die 5) Down time and usable product 6) Upstream/down stream processing Extrusion Line Audit

1)Install larger motor (more available kW) 2)Check with extruder manufacturer on design limitations 3)Factor in effects of improved preconditioning and other process improvements Increasing Power to Drive Extruder Extrusion Line Audit

Factors That Potentially Limit Capacity of Extruders 1) Preconditioning capacity 2) Available power to the extruder 3) Volumetric capacity of extruder 4) Open area in die 5) Down time and usable product 6) Upstream/down stream processing Extrusion Line Audit

Increase Volumetric Capacity of Extruders 1)Larger extruder screw diameter 2)Increase extruder shaft speed 3)New inlet screw designs with more conveying volume 4)Grooved barrel liners 5)Control of extruder barrel temperatures

Factors That Potentially Limit Capacity of Extruders 1) Preconditioning capacity 2) Available power to the extruder 3) Volumetric capacity of extruder 4) Open area in die 5) Down time and usable product 6) Upstream/down stream processing Extrusion Line Audit

Increasing open area of die orifices 1)Use wear plate assemblies 2)Flare-out to larger die plates

Move to die designs that permit more die orifices on a given surface area Insert die holderWear plates assembly

Factors That Potentially Limit Capacity of Extruders 1) Preconditioning capacity 2) Available power to the extruder 3) Volumetric capacity of extruder 4) Open area in die 5) Down time and usable product 6) Upstream/down stream processing Extrusion Line Audit

Down-Time 1)Plants that believe they operate 24/7 may still have 20% down time annually 2)Example: 10 ton/hr system down for 30 minutes is 5 ton of lost production 3)Increase average capacity especially with short production runs

To Reduce Down-Time 1)Scheduling 2)Hardware tools for “quick-change” 3)Control or software systems that compress shutdown and startup times 4)Operator training and experience 5)Preventative maintenance 6)New hardware design technologies (that allow easy access for maintenance and sanitation)

Increase Usable Product (decrease off-spec material) 1)Automated Retention Time Control in DDC preconditioner 2)Screw element and liner designs to give positive conveyance 3)High extruder speeds and variable-speed drives 4)Automated control systems (SME, fat, etc.) 5)Warm-restart control systems compress startup time to less than 1 minute 6)Operator experience and training 7)Gentle product handling 8)Systems to recycle under-processed material

Factors That Potentially Limit Capacity of Extruders 1) Preconditioning capacity 2) Available power to the extruder 3) Volumetric capacity of extruder 4) Open area in die 5) Down time and usable product 6) Upstream/down stream processing Extrusion Line Audit

Grinding, sifting, storage, conveying, drying, cooling, coating, and packaging are all unit operations that must be sized properly to avoid a flow bottleneck!

Eliminating the bottlenecks can result in a 50% increase in annual throughputs for a given line! 1) Preconditioning capacity 2) Available power to the extruder 3) Volumetric capacity of extruder 4) Open area in die 5) Down time and usable product 6) Upstream/down stream processing Extrusion Line Audit “Aquafeed Horizons” WORKSHOP